Folded Plate Heat Exchanger Layout to Prevent Boiler Water Boiling
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Solution Overview
Problem
Existing plate heat exchangers for condensing boilers face issues such as high material waste, increased manufacturing costs, and water boiling due to insufficient water flow speed and amount, particularly around the combustion chamber, which complicates heat exchange efficiency and requires costly solutions to prevent clogging from mineral deposits.
Innovation Solution
A plate heat exchanger design featuring rectangular plates made from a single folded sheet metal with strategically formed channels and gaskets, allowing water to flow in series or parallel configurations to manage high temperatures while minimizing material waste and optimizing heat exchange efficiency, with the combustion products passing through gaps between plates, and using containment plates and casings to manage water flow and prevent boiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If larger holes are formed in plates to create fumes collectors, then the combustion chamber can be housed, but significant sheet metal scraps are produced increasing manufacturing costs
Solution Approach 1:
The plate is divided into distinct functional zones: a rectangular body for heat exchange and separate C-shaped wings for combustion chamber housing. This segmentation allows each part to fulfill its specific function without compromising the other, eliminating material waste while maintaining adaptability
Solution Approach 2:
The C-shaped wings serve multiple functions: they form the combustion chamber housing, provide structural support, and maintain thermal isolation. This multi-functionality eliminates the need for separate components, reducing material waste while preserving combustion chamber capability
2Productivity
If water flows in parallel channels, then heat exchange efficiency is maintained, but water speed is insufficient causing boiling in high thermal load areas
Solution Approach 1:
The system dynamically adapts water flow configuration based on thermal load requirements. In high thermal load zones (combustion chamber area), water flows in series to increase speed and prevent boiling. In lower thermal load zones, parallel flow maintains heat exchange efficiency. This dynamic switching resolves the contradiction between speed and efficiency
Solution Approach 2:
Different flow configurations are applied to different zones of the heat exchanger. The C-shaped wings experience series flow for high speed, while the rectangular body utilizes parallel flow for efficient heat exchange. This local differentiation allows each zone to operate optimally without compromising overall system performance
3Object-affected harmful factors
If fixed paths with limited passage section are created to increase water speed, then boiling is prevented, but limestone deposits rapidly clog the pipes
Solution Approach 1:
The C-shaped wings provide a three-dimensional flow path that increases water speed through geometric configuration rather than constricting the passage section. The curved path creates velocity increase without reducing cross-sectional area, preventing both boiling and limestone deposition simultaneously
4Adaptability or versatility
If circular or C-shaped plates are used to delimit fumes circuit, then containment is achieved, but large sheet metal waste occurs
Solution Approach 1:
The plate is segmented into a rectangular body and C-shaped wings, where the wings provide containment functionality. This segmentation allows the use of efficient rectangular sheet utilization while the wings extend to provide the necessary containment shape without wasting material
Solution Approach 2:
The C-shaped wings introduce asymmetric geometry only where functionally required for combustion chamber housing and fumes containment. The main body remains rectangular for material efficiency. This asymmetric addition provides containment capability with minimal material waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design reduces material waste, lowers manufacturing costs, and effectively prevents water boiling by optimizing water flow speed and temperature management, maintaining high heat exchange efficiency while minimizing thermal load loss, suitable for various boiler applications.
Implementation Method 1
The inlet and outlet collectors of the fumes are opposite and are close to, respectively, outlet and inlet collectors of the water, thus leading to a very efficient heat exchange called counter-current
Implementation Method 2
water and fumes run along parallel channels
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A heat exchanger (1) for boilers (100), in particular for condensing boilers. The heat exchanger (1) comprises a set of heat exchanging plates (2, 2*) inside which the water to be heated flows and outside which the combustion products (3) coming from a burner (4) pass. The heat exchanger (1) is characterized in that it comprises a plurality of plates (2, 2*) coupled to a plurality of diaphragms (50) for closing openings (28, 29, 30, 31) present on the plates (2, 2*); each plate (2, 2*) comprising at least two levels ((I), (II), (III)) of respective channels (23, 24, 25) for the water flow to be heated. Hydraulic connections in series between the channels (25) can be provided on the layer (III) closest to a burner (4).